Sustainable injection molded articles

ABSTRACT

A sustainable thermoplastic composition made by forming a mixture of virgin polypropylene and post-industrial-recycled material (PIR). The PIR may include a thermoplastic, elastomeric-polymer and a spunbond component. The mixture is melt-blended in an extruder. Extruded materials made from the mixture demonstrate little variance in the results of the IZOD Impact Test of materials containing 30 to 70 percent PIR, and a material containing 100 percent virgin polypropylene. In addition, the extruded materials containing 30 to 70 percent PIR demonstrate a substantially constant strain at yield, that strain at yield being substantially equal to that demonstrated by a material containing 100 percent virgin polypropylene.

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.14/138,325, filed Dec. 23, 2013, which claims the benefit of U.S.Provisional Application No. 61/860,577, filed on Jul. 31, 2013. Theentirety of Application No. 61/860,577 is incorporated herein byreference.

FIELD OF THE DISCLOSURE

The present disclosure relates to compositions for making injectionmolded articles, the compositions including virgin polymers and recycledmaterial obtained from an industrial waste stream, and the methods ofmaking sustainable injection molded articles.

BACKGROUND OF THE DISCLOSURE

The use of injection-molded plastic packaging has become a mainstay forpackaging consumer products, especially those that have a highermoisture content, such as wet wipes. One advantage of such packaging isthat it can designed to conveniently dispense product. However, suchpackaging can be expensive, adding to the cost of the overall product.In addition, such packaging is typically made from virginpetroleum-derived polymers formulated with materials that fluctuategreatly in price. Furthermore, injection molded articles made fromvirgin polymers have a high environmental foot print, otherwise referredto as a high “eCO₂”. (The eCO₂ for a given material is determined by amaterial life cycle analysis wherein a method of measuring carbonequivalents is used to obtain the overall carbon footprint.) This isprimarily due to the inherent high energy input used to produce thevirgin polymers, and the resulting green-house gas emissions.

One solution to the high expense of injection molded packaging or otherarticles is to substitute a portion of the virgin polymers withrecycled-content polymers. Such material may consist of post-consumerplastic waste. However, even though the addition of recycled contentreduces cost, relying on post-consumer waste as a material supply is notnecessarily advantageous because the physical properties of theresulting injection-molded articles (e.g. packaging) may vary and maynot be adequate. With respect to plastic packaging, retailers andconsumers may drop packages which may cause cracking and other damage tothe package. Therefore, packaging material needs to be able to withstanda certain level of impact without cracking or otherwise failing.

A need exists for a composition that consistently exhibits physicalproperties within a desired range, such as impact strength and strain atfailure. Further, there is a need for compositions that are sustainablein that they are made from waste or by-products, and not made solelyfrom virgin materials. In addition, there is a need for a compositionthat produces injection-molded articles that are less costly thancompositions of 100% virgin materials.

SUMMARY

The present disclosure in accordance with one aspect pertains to amethod for forming a sustainable thermoplastic composition for injectionmolding. The method includes the step of forming a mixture by supplyinga virgin polymer and a post-industrial-recycled material (PIR) to a feedsection of an extruder, wherein the PIR comprises a thermoplastic,elastomeric-polymer and a spunbond component. The method furtherincludes the step of melt processing the mixture within the extruder toform the thermoplastic composition.

Another aspect of the disclosure is directed to a thermoplastic materialthat is made with 30 to 70 parts by weight of 100% virgin polymer. Thevirgin polymer is selected from the the following: polypropylene,polyethylene, polystyrene, acrylonitrile-butadiene-styrene copolymers,polylactic acid, blends of polylactic acid and polyolefins andcombinations thereof. The remainder of the thermoplastic materialcomposition is post-industrial-recycled material (PIR).

Yet another aspect of the disclosure is a thermoplastic extrudedarticle. The article includes a core layer of material having 30 to 70parts by weight of 100% virgin polymer. The virgin polymer may beselected from the following: polypropylene, polyethylene, polystyrene,acrylonitrile-butadiene-styrene copolymers, polylactic acid, blends ofpolylactic acid and polyolefins and combinations thereof. The remainerof the article composition is post-industrial-recycled material (PIR).

Other features and aspects of the present disclosure are discussed ingreater detail below.

BRIEF DESCRIPTION OF FIGURES

A full and enabling disclosure of the present invention, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth more particularly in the remainder of the specification, whichmakes reference to the appended figures in which:

FIG. 1 is a partially broken away side view of an extruder that may beused in one embodiment of the present invention;

FIG. 2 is a plan view of an ASTM specimen mold from which Izod test andtensile test samples were generated;

FIG. 3 is a graph that shows the impact strength of Izod specimensprepared according to FIG. 2, as a function of composition.

FIG. 4 is a graph that shows the strain at failure of tensile barsprepared according to FIG. 2, as a function of composition.

FIG. 5 is a graph showing the strain at failure of tensile bars preparedaccording to FIG. 2, as a function of composition;

FIG. 6 is a micrograph of a cross-section of a tensile bar according toFIG. 2, injection molded from a 30/70 blend of virgin polymer/reclaimedSBL;

FIG. 7 is a micrograph of a cross-section of a tensile bar according toFIG. 2, injection molded from a 70/30 blend of virgin polymer/reclaimedSBL;

FIG. 8 is a micrograph of a cross-section of a tensile bar according toFIG. 2, injection molded from virgin polymer;

FIG. 9 is a micrograph of a cross-section of a tensile bar according toFIG. 2, injection molded from SBL;

FIG. 10 is a micrograph showing the distribution of crystalline materialacross the tensile bar according to FIG. 2, for virgin polymer;

FIG. 11 is a micrograph showing the distribution of crystalline materialacross the tensile bar according to FIG. 2, for SBL;

FIG. 12 is a micrograph of the edge of a tensile bar according to FIG.2, for SBL;

FIG. 13 is a micrograph of a tensile bar according to FIG. 2, for virginpolymer;

FIG. 14 is a micrograph of an etched surface of a tensile bar accordingto FIG. 2, showing the topography of a virgin polymer;

FIG. 15 is a micrograph of an etched surface of a tensile bar accordingto FIG. 2, showing the topography of SBL;

FIG. 16 is one embodiment of a wet wipe package that is injection moldedfrom the material of the present disclosure; and

FIG. 17 is one embodiment of the material the may be used to manufacturethe wet wipe package of FIG. 16.

Repeat use of reference characters in the present specification anddrawings is intended to represent same or analogous features or elementsof the invention.

DETAILED DESCRIPTION Section I. —Definitions

“Adhesive spun-bond film laminate” (otherwise referred to as “aSFL”) asused herein is a laminate of a nonwoven facing and a breathablepolyethylene film with an adhesive between the nonwoven facing andpolethylene films. One example of the nonwoven facing is a polypropylenespunbond. Another example is a polyethylene breathable film made from acalcium-carbonate-filled polyethylene stretched in the machine directionto create a microporous film that is breathable to allow moisture topass through the film. One example of aSFL is disclosed in U.S. Pat. No.7,812,214, incorporated herein by reference.

“Articles” as used herein refer to any injection-molded item, regardlessof it's end use. Articles used in the field of packaging are referencedas only one example of items made from the composition of the presentdisclosure.

“Elastomer” as used herein refers to a thermoplastic elastomericpolymer. Such a polymer has a low Young's modulus, high recoverabledeformation, and high yield strain as compared with other polymermaterials.

“Post industrial recycle” (otherwise referred to as “PIR”) as usedherein is a material obtained from the manufacture of productscontaining stretch-bond laminate and/or adhesive spun-bond laminate asdefined herein.

“Meltblown” refers to fibers formed by extruding a molten thermoplasticmaterial through a plurality of fine, usually circular, die capillariesas molten threads or filaments into converging high velocity gas (e.g.,air) streams, generally heated, which attenuate the filaments of moltenthermoplastic material to reduce their diameters. Thereafter, themeltblown fibers are carried by the high velocity gas stream and aredeposited on a collecting surface or support to form a web of randomlydispersed meltblown fibers. Such a process is disclosed, for example, inU.S. Pat. No. 3,849,241 to Butin et al. Meltblowing processes can beused to make fibers of various dimensions, including macrofibers (withaverage diameters from about 40 to about 100 microns), textile-typefibers (with average diameters between about 10 and 40 microns), andmicrofibers (with average diameters less than about 10 microns).Meltblowing processes are particularly suited to making microfibers,including ultra-fine microfibers (with an average diameter of about 3microns or less). A description of an exemplary process of makingultra-fine microfibers may be found in, for example, U.S. Pat. No.5,213,881 to Timmons et al. Meltblown fibers may be continuous ordiscontinuous and are generally self bonding when deposited onto acollecting surface.

“Nonwoven” and “nonwoven web” refer to materials and webs of materialthat are formed without the aid of a textile weaving or knittingprocess. For example, nonwoven materials, fabrics or webs have beenformed from many processes such as, for example, meltblowing processes,spunbonding processes, air laying processes, coform processes, andbonded carded web processes.

“Spunbonded fibers” refers to small diameter fibers which are formed byextruding molten thermoplastic material as filaments from a plurality offine, usually circular capillaries of a spinneret with the diameter ofthe extruded filaments then being rapidly reduced to fibers as by, forexample, in U.S. Pat. No. 4,340,563 to Appel et al.; U.S. Pat. No.3,692,618 to Dorschner et al.; U.S. Pat. No. 3,802,817 to Matsuki etal.; U.S. Pat. Nos. 3,338,992 and 3,341,394 to Kinney; U.S. Pat. No.3,502,763 to Hartman; and U.S. Pat. No. 3,542,615 to Dobo et al., thecontents of which are incorporated herein by reference in theirentirety. Spunbond fibers are generally continuous and have diametersgenerally greater than about 7 microns, more particularly, between about10 and about 20 microns.

“Spun-bonded laminate” (“SBL”) refers to a composite material having atleast two layers in which one layer is a gatherable layer and the otherlayer is an elastic layer. The layers are joined together when theelastic layer is extended from its original condition so that uponrelaxing the layers, the gatherable layer is gathered. Such a multilayercomposite elastic material may be stretched to the extent that thenonelastic material gathered between the bond locations allows theelastic material to elongate. One type of stretch bonded laminate isdisclosed, for example, by U.S. Pat. No. 4,720,415 to Vander Wielen etal., the content of which is incorporated herein by reference in itsentirety. Other composite elastic materials are disclosed in U.S. Pat.No. 4,789,699 to Kieffer et al.; U.S. Pat. No. 4,781,966 to Taylor; U.S.Pat. Nos. 4,657,802 and 4,652,487 to Morman; and U.S. Pat. No. 4,655,760to Morman et al.; U.S. Pat. No. 5,366,793 to Fitts Jr. et al.; U.S. Pat.No. 5,385,775 to Wright; U.S. Pat. No. 5,514,470 to Haffner et al.; U.S.Pat. No. 6,902,796 to Morell et al.; U.S. Pat. No. 7,803,244 toSiqueira, et al.; the contents of which are incorporated herein byreference in their entirety.

“Virgin polymer” as used herein refers specifically to polypropelene(otherwise referred to as “PP”). Desirably, the polypropylene is 100percent prime, containing no recycled content. However, it isanticipated that off-prime polypropylene may be used in the presentdisclosure.

Section II. —Description

The present disclosure addresses some of the problematic issues withcurrent sustainable materials in that the articles of the presentdisclosure are made from recycled materials, PIR, that are moreconsistent with respect to content than post-consumer recycled materialsor virgin materials. Such articles have more consistent and desirablephysical properties, and are less costly than articles made from 100%prime polymer, which is a virgin polymer. The present disclosurediscusses the method of making compositions containing PIR, the methodof making articles from the compositions, and the physical properties ofthe articles.

A. Components a) Spun-Bonded Laminate (“SBL”)

In general, the present disclosure pertains to thermoplastic polymercompositions containing virgin polymer and post industrial recycle(“PIR”). In a most desired aspect of the disclosure, the PIR is SBL.

As described supra, SBL is generally a composite material having atleast on layer of elastomeric material sandwiched between non-elasticmaterial. In one specific aspect of the disclosure, the SBL may havethree layers. Generally, the outer layers may be composed of webs ofnonelastic, nonwoven, polymer fibers. These fibers are desirablyspunbond. The middle layer is made from amorphous polymer fibers. Thefibers of the middle layer may be formed from, for example, elastomericpolystyrene/poly(ethylenebutylene)/polystyrene) block copolymers; lineartri-block copolymer based on styrene, ethylene/butylene and polystyrene;or styrene-butadiene-styrene block copolymer, thermoplastic polyurethane(described below in more detail), thermoplastic polyolefins (alsodescribed below in more detail), etc. Commercial examples of such asuitable copolymer includes KRATON, available from Kraton Polymers U.S.LLC, Houston, Tex. KRATON styrenic, thermoplastic, block-copolymers areavailable in several different formulations, a number of which areidentified in U.S. Pat. Nos. 4,663,220 and 5,304,599, herebyincorporated by reference.

Thermoplastic Polyurethane

Thermoplastic polyurethanes are generally synthesized from a polyol,organic diisocyanate, and optionally a chain extender. The synthesis ofsuch melt-processable polyurethane elastomers may proceed eitherstepwise (e.g., prepolymer dispensing process) or by simultaneousreaction of all components in a single stage (e.g., one-shot dispensingprocess) as is known in the art and described in more detail in U.S.Pat. No. 3,963,656 to Meisert, et al.; U.S. Pat. No. 5,605,961 to Lee,et al.; U.S. Pat. No. 6,008,276 to Kalbe, et al.; U.S. Pat. No.6,417,313 to Kirchmeyer, et al.; and U.S. Pat. No. 7,045,650 to Lawrey,et al., as well as U.S. Patent Application Publication Nos. 2006/0135728to Peerlings, et al. and 2007/0049719 to Brauer, et al., all of whichare incorporated herein in their entirety by reference thereto for allpurposes.

A polyol is generally any high molecular weight product having an activehydrogen component that may be reacted and includes materials having anaverage of about two or more hydroxyl groups per molecule. Long-chainpolyols may be used that include higher polymeric polyols, such aspolyester polyols and polyether polyols, as well as other acceptable“polyol” reactants, which have an active hydrogen component such aspolyester polyols, polyhydroxy polyester amides, hydroxyl containingpolycaprolactones, hydroxy-containing acrylic interpolymers,hydroxy-containing epoxies, and hydrophobic polyalkylene ether polyols.Typically, the polyol is substantially linear and has two to three, andmore preferably two hydroxyl groups, and a number average molecularweight of from about 450 to about 10,000, in some embodiments from about450 to about 6000, and in some embodiments from about 600 to about 4500.Suitable polyether dials may be produced by, for example, reacting oneor more alkylene oxides having 2 to 4 carbon atoms in the alkyleneresidue with a starter molecule that contains two or more activehydrogen atoms in bound form. Exemplary alkylene oxides include ethyleneoxide, 1,2-propylene oxide, epichlorohydrin and 1,2-butylene oxide and2,3-butylene oxide. Exemplary starter molecules include water;aminoalcohols, such as N-alkyl-diethanolamines (e.g.,N-methyl-diethanolamine); and diols, such as ethylene glycol,1,3-propylene glycol, 1,4-butanediol and 1,6-hexanediol. Suitablepolyester diols may be produced from dicarboxylic acids (or derivativesthereof) having 2 to 12 carbon atoms, preferably 4 to 6 carbon atoms,and polyhydric alcohols. Exemplary dicarboxylic acids include aliphaticdicarboxylic acids, such as succinic acid, glutaric acid, adipic acid,suberic acid, azelaic acid and sebacic acid; aromatic dicarboxylicacids, such as phthalic acid, isophthalic acid and terephthalic acid; aswell as derivatives of such acids, such as carboxylic acid diestershaving 1 to 4 carbon atoms in the alcohol residue, carboxylic anhydridesor carboxylic acid chlorides. Examples of suitable polyhydric alcoholsinclude glycols with 2 to 10, preferably 2 to 6 carbon atoms, such asethylene glycol, diethylene glycol, 1,4-butanediol, 1,5-pentanediol,1,6-hexanediol, 1,10-decanediol, 2,2-dimethyl-1,3-propanediol,1,3-propanediol, and dipropylene glycol. Esters of carbonic acid withthe stated diols are also suitable, and particularly, those having 4 to6 carbon atoms, such as 1,4-butanediol or 1,6-hexanediol; condensationproducts of co-hydroxycarboxylic acids, such as ?-hydroxycaproic acid orpolymerisation products of lactones (e.g., optionally substituted?-caprolactones). Preferred polyester diols include ethanediolpolyadipates, 1,4-butanediol polyadipates, ethanediol/1,4-butanediolpolyadipates, 1,6-hexanediol/neopentyl glycol polyadipates,1,6-hexanediol/1,4-butanediol polyadipates and polycaproplactones.

The organic diisocyanates may include aliphatic diisocyanates, such asethylene diisocyanate, 1,4-tetramethylene diisocyanate, 1,12-dodecanediisocyanate, 1,6-hexamethylene diisocyanate, mixtures thereof, etc.;cycloaliphatic diisocyanates, such as isophorone diisocyanate,1,4-cyclohexane diisocyanate, 1-methyl-2,4-cyclohexane diisocyanate,1-methyl-2,6-cyclohexane diisocyanate, 4,4′-, 2,4′- or2,2′-dicyclohexylmethane diisocyanate, mixtures thereof, etc.; and/oraromatic diisocyanates, such as 2,4- or 2,6-toluene diisocyanate,4,4′-diphenylmethane diisocyanate, 2,4′-diphenylmethane diisocyanate,2,2′-diphenylmethane diisocyanate, naphthylene-1,5-diisocyanate,xylylene diisocyanate, methylene diphenyl isocyanate (“MDI”),hexamethylene diisocyanate (“HMDI”), mixtures thereof, etc.

The chain extenders typically have a number average molecular weight offrom about 60 to about 400 and contains amino, thiol, carboxyl, and/orhydroxyl functional groups. The preferred chain extenders are thosehaving two to three, and more preferably two, hydroxyl groups. As setforth above, one or more compounds selected from the aliphatic diolsthat contain from 2 to 14 carbon atoms may be used as the chainextender. Such compounds include, for example, ethanediol,1,2-propanediol, 1,3-propanediol, 1,4-butanediol, 2,3-butanediol,1,5-pentanediol, 1,6-hexanediol, diethylene glycol, dipropylene glycol,1,4-cyclohexanediol, 1,4-dimethanolcyclohexane and neopentyl glycol,Diesters of terephthalic acid with glycols having 2 to 4 carbon atomsmay also be employed. Some examples of such compounds includeterephthalic acid bis-ethylene glycol and terephthalic acidbis-1,4-butanediol, hydroxyalkylene ethers of hydroquinone (e.g.,1-4-di(beta-hydroxyethyl)hydroquinone), ethoxylated bisphenols (e.g.,1,4-di(beta-hydroxyethyObisphenol A), (cyclo)aliphatic diamines (e.g.,isophoronediamine, ethylendiamine, 1,2-propylenediamine,1,3-propylenediannine, N-methyl-1,3-propylenediamine, andN,N′-dimethylethyiene-diamine), and aromatic diamines (e.g.,2,4-toluenediamine, 2,6-toluenediamine, 3,5-diethyl-2,4-toluenediamineand 3,5-diethyl-2,6-toluenediamine, and primary mono-, di-, tri- ortetraalkyl-substituted 4,4′-diaminodiphenylmethanes).

In addition to those noted above, other components may also be employedto form the thermoplastic polyurethane. Catalysts, for instance, may beemployed to facilitate formation of the polyurethane. Suitable catalystsinclude, for instance, tertiary amines, such as triethylamine,dimethylcyclohexyl-amine, N-methylmorpholine, N,N′-dimethylpiperazine,2-(dimethylaminoethoxy)-ethanol, diazabicyclo[2.2.2]octane, etc. as wellas metal compounds, such as titanic acid esters, tin diacetate, tindioctoate, tin dilaurate or the dialkyltin salts of aliphatic carboxylicacids such as dibutyltin diacetate or dibutyltin dilaurate or othersimilar compounds. Still other suitable additives that may be employedinclude light stabilizers (e.g., hindered amines), chain terminators,slip agents and mold release agents (e.g., fatty acid esters, the metalsoaps thereof, fatty acid amides, fatty acid ester amides and siliconecompounds), plasticizers, antiblocking agents, inhibitors, stabilizersagainst hydrolysis, heat and discoloration, dyes, pigments, inorganicand/or organic fillers, fungistatically and bacteriostatically activesubstances, fillers, etc.

The thermoplastic polyurethane typically has a melting point of fromabout 75 degrees centigrade to about 250 degrees centigrade, in someembodiments from about 100 degrees centigrade to about 240 degreescentigrade, and in some embodiments, from about 120 degrees centigradeto about 220 degrees centigrade The glass transition temperature (“Tg”)of the thermoplastic polyurethane may be relatively low, such as fromabout −150 degrees centigrade to about 0 degrees centigrade, in someembodiments from about −100 degrees centigrade to about −10 degreescentigrade, and in some embodiments, from about −85 degrees centigradeto about −20 degrees centigrade The melting temperature and glasstransition temperature may be determined using differential scanningcalorimetry (“DSC”) in accordance with ASTM D-3417. Examples of suchthermoplastic polyurethanes are available under the designationDESMOPAN™ from Bayer MaterialScience and under the designation ESTANE™from Lubrizol. DESMOPAN™ DP 9370A, for instance, is an aromaticpolyether-based polyurethane formed from poly(tetramethylene etherglycol) and 4,4-methylenebis(phenylisocyanate) (“MDI”) and has a glasstransition temperature of about −70 degrees centigrade and a meltingtemperature of from about 188 degrees centigrade to about 199 degreescentigrade ESTANE™ 58245 is likewise an aromatic polyether-basedpolyurethane having a glass transition temperature of about −37 degreescentigrade and a melting temperature of from about 135 degreescentigrade to about 159 degrees centigrade.

Olefinic Elastomer

Various olefinic elastomers may be employed in the film as is known inthe art. In one embodiment, for example, the olefinic elastomer is apolyolefin that has or is capable of exhibiting a substantially regularstructure (“semi-crystalline”). Such olefinic elastomers may besubstantially amorphous in their undeformed state, but form crystallinedomains upon stretching. The degree of crystallinity of the olefinpolymer may be from about 3 percent to about 30 percent, in someembodiments from about 5 percent to about 25 percent, and in someembodiments, from about 5 percent and about 15 percent. Likewise, theolefinic elastomer may have a latent heat of fusion (ΔHf), which isanother indicator of the degree of crystallinity, of from about 15 toabout 75 Joules per gram (“J/g”), in some embodiments from about 20 toabout 65 J/g, and in some embodiments, from 25 to about 50 J/g. Theolefinic elastomer may also have a Vicat softening temperature of fromabout 10 degrees centigrade to about 100 degrees centigrade, in someembodiments from about 20 degrees centigrade to about 80 degreescentigrade, and in some embodiments, from about 30 degrees centigrade toabout 60 degrees centigrade The olefinic elastomer may have a meltingtemperature of from about 20 degrees centigrade to about 120 degreescentigrade, in some embodiments from about 35 degrees centigrade toabout 90 degrees centigrade, and in some embodiments, from about 40degrees centigrade to about 80 degrees centigrade The latent heat offusion (DELTAHf) and melting temperature may be determined usingdifferential scanning calorimetry (“DSC”) in accordance with ASTM D-3417as is well known to those skilled in the art. The Vicat softeningtemperature may be determined in accordance with ASTM D-1525.

Exemplary semi-crystalline olefinic elastomers include polyethylene,polypropylene, blends and copolymers thereof. In one particularembodiment, a polyethylene is employed that is a copolymer of ethyleneand an α-olefin, such as a C3-C20 α-olefin or C3-C12 α-olefin. Suitableα-olefins may be linear or branched (e.g., one or more C1-C3 alkylbranches, or an aryl group). Specific examples include 1-butene;3-methyl-1-butene; 3,3-dimethyl-1-butene; 1-pentene; 1-pentene with oneor more methyl, ethyl or propyl substituents; 1-hexene with one or moremethyl, ethyl or propyl substituents; 1-heptene with one or more methyl,ethyl or propyl substituents; 1-octene with one or more methyl, ethyl orpropyl substituents; 1-nonene with one or more methyl, ethyl or propylsubstituents; ethyl, methyl or dimethyl-substituted 1-decene;1-dodecene; and styrene. Particularly desired α-olefin comonomers are1-butene, 1-hexene and 1-octene. The ethylene content of such copolymersmay be from about 60 mole percent to about 99 mole percent, in someembodiments from about 80 mole percent to about 98.5 mole percent, andin some embodiments, from about 87 mole percent to about 97.5 molepercent. The α-olefin content may likewise range from about 1 molepercent to about 40 mole percent, in some embodiments from about 1.5mole percent to about 15 mole percent, and in some embodiments, fromabout 2.5 mole percent to about 13 mole percent. Propylene polymers mayalso be suitable for use as an olefinic elastomer. In one particularembodiment, the semi-crystalline propylene-based polymer includes acopolymer of propylene and an α-olefin, such as a C2-C20 α-olefin orC2-C12 α-olefin. Particularly desired α-olefin comonomers are ethylene,1-butene, 1-hexene and 1-octene. The propylene content of suchcopolymers may be from about 60 mole percent to about 99.5 weightpercent, in some embodiments from about 80 mole percent to about 99 molepercent, and in some embodiments, from about 85 mole percent to about 98mole percent. The α-olefin content may likewise range from about 0.5mole percent to about 40 mole percent, in some embodiments from about 1mole percent to about 20 mole percent, and in some embodiments, fromabout 2 mole percent to about 15 mole percent.

Any of a variety of known techniques may generally be employed to formthe olefinic elastomers. For instance, olefin polymers may be formedusing a free radical or a coordination catalyst (e.g., Ziegler-Natta).Preferably, the olefin polymer is formed from a single-site coordinationcatalyst, such as a metallocene catalyst. Such a catalyst systemproduces ethylene copolymers in which the comonomer is randomlydistributed within a molecular chain and uniformly distributed acrossthe different molecular weight fractions. Metallocene-catalyzedpolyolefins are described, for instance, in U.S. Pat. No. 5,571,619 toMcAlpin et al.; U.S. Pat. No. 5,322,728 to Davis et al.; U.S. Pat. No.5,472,775 to Obioeski et al.; U.S. Pat. No. 5,272,236 to Lai et al.; andU.S. Pat. No. 6,090,325 to Wheat, et al., which are incorporated hereinin their entirety by reference thereto for all purposes. Examples ofmetallocene catalysts include bis(n-butylcyclopentadienyl)titaniumdichloride, bis(n-butylcyclopentadienyl)zirconium dichloride,bis(cyclopentadienyl)scandium chloride, bis(indenyl)zirconiumdichloride, bis(methylcyclopentadienyl)titanium dichloride,bis(methylcyclopentadienyl)zirconium dichloride, cobaltocene,cyclopentadienyltitanium trichloride, ferrocene, hafnocene dichloride,isopropyl(cyclopentadienyl,-1-flourenyl)zirconium dichloride,molybdocene dichloride, nickelocene, niobocene dichloride, ruthenocene,titanocene dichloride, zirconocene chloride hydride, zirconocenedichloride, and so forth. Polymers made using metallocene catalyststypically have a narrow molecular weight range.

For instance, metallocene-catalyzed polymers may have polydispersitynumbers (Mw/Mn) of below 4, controlled short chain branchingdistribution, and controlled isotacticity.

The density of such α-olefin copolymers is a function of both the lengthand amount of the α-olefin. That is, the greater the length of theα-olefin and the greater the amount of α-olefin present, the lower thedensity of the copolymer. Although not necessarily required,substantially linear elastomers are particularly desirable in that thecontent of α-olefin short chain branching content is such that thecopolymer exhibits both plastic and elastomeric characteristics. Becausepolymerization with α-olefin comonomers decreases crystallinity anddensity, the resulting elastomer normally has a density lower than thatof polyethylene thermoplastic polymers (e.g., LLDPE), but approachingand/or overlapping that of other elastomers. For example, the density ofthe olefinic elastomer may be about 0.91 grams per cubic centimeter(g/cm3) or less, in some embodiments from about 0.85 to about 0.89g/cm3, and in some embodiments, from about 0.85 g/cm3 to about 0.88g/cm3.

Preferred ethylene elastomers for use in the present invention areethylene-based copolymer plastomers available under the EXACT™ fromExxonMobil Chemical Company of Houston, Tex. Other suitable polyethyleneplastomers are available under the designation ENGAGE™ and AFFINITY™from Dow Chemical Company of Midland, Mich. Still other suitableethylene polymers are available from The Dow Chemical Company under thedesignations DOWLEX™ (LLDPE) and ATTANE™ (ULDPE). Such ethylene polymersare described in U.S. Pat. No. 4,937,299 to Ewen et al.; U.S. Pat. No.5,218,071 to Tsutsui et al.; U.S. Pat. No. 5,272,236 to Lai, et al.; andU.S. Pat. No. 5,278,272 to Lai, et al., which are incorporated herein intheir entirety by reference thereto for all purposes. Suitable propylenepolymers are commercially available under the designations VISTAMAXX™from ExxonMobil Chemical Co. of Houston, Tex.; FINA™ (e.g., 8573) fromAtofina Chemicals of Feluy, Belgium; TAFMER™ available from MitsuiPetrochemical Industries; and VERSIFY™ available from Dow Chemical Co.of Midland, Mich. Other examples of suitable propylene polymers aredescribed in U.S. Pat. No. 6,500,563 to Datta, et al.; U.S. Pat. No.5,539,056 to Yang, et al.; and U.S. Pat. No. 5,596,052 to Resconi, etal., which are incorporated herein in their entirety by referencethereto for all purposes.

The melt flow index (MI) of the olefinic elastomers may generally vary,but is typically in the range of about 0.1 grams per 10 minutes to about100 grams per 10 minutes, in some embodiments from about 0.5 grams per10 minutes to about 30 grams per 10 minutes, and in some embodiments,about 1 to about 10 grams per 10 minutes, determined at 190 degreescentigrade The melt flow index is the weight of the polymer (in grams)that may be forced through an extrusion rheometer orifice (0.0825-inchdiameter) when subjected to a force of 2.16 kilograms in 10 minutes at190 degrees centigrade, and may be determined in accordance with ASTMTest Method D1238-E.

Of course, other olefinic elastomers may also be employed in the presentinvention. In one embodiment, for example, the thermoplastic elastomermay be a styrene-olefin block copolymer, such asstyrene-(ethylene-butylene), styrene-(ethylene-propylene),styrene-(ethylene-butylene)-styrene,styrene-(ethylene-propylene)-styrene,styrene-(ethylene-butylene)-styrene-(ethylene-butylene),styrene-(ethylene-propylene)-styrene-(ethylene-propylene), andstyrene-ethylene-(ethylene-propylene)-styrene. Such polymers may beformed by selective hydrogenation of styrene-diene block copolymers,such as described in U.S. Pat. Nos. 4,663,220, 4,323,534, 4,834,738,5,093,422 and 5,304,599, which are hereby incorporated in their entiretyby reference thereto for all purposes. Particularly suitablethermoplastic elastomers are available from Kraton Polymers LLC ofHouston, Tex. under the trade name KRATON®. Other commercially availableblock copolymers include the S-EP-S elastomeric copolymers availablefrom Kuraray Company, Ltd. of Okayama, Japan, under the tradedesignation SEPTON®. Also suitable are polymers composed of an A-B-A-Btetrablock copolymer, such as discussed in U.S. Pat. No. 5,332,613 toTaylor, et al., which is incorporated herein in its entirety byreference thereto for all purposes. An example of such a tetrablockcopolymer is astyrene-poly(ethylene-propylene)-styrene-poly(ethylene-propylene)(“S-EP-S-EP”) block copolymer.

In another aspect of the disclosure, the SBL has four layers made fromthe following: i) a first layer of substantially parallel filamentsformed of an elastomeric polymer, the elastomeric polymer having anaverage molecular weight of from about 65,000 g/mol to about 100,000g/mol; ii) a second layer of elastomeric meltblown fibers, the meltblownfibers bonded to at least a portion of the first layer filaments; iii) athird layer of spunbond fibers; and iv) a fourth layer of spunbondfibers. The first and second layers are disposed between the third andfourth layers.

There are many other types of SBL that may be used in the presentdiclosure, and the two examples are not meant to be limiting.

b) Polymer

The article of the present disclosure also includes a polymer such aspolypropylene, polyethylenes including high density polyethylene, linearlow density polyethylene, ethylene copolymers such aspoly(ethylene-co-propylene), poly(ethylene-co-vinyl acetate (EVA), etc.polystyrene, polyethyelne terephthalate (PET), polylactic acid (PLA),blends of PLA with polyolefins such as polypropylene or high densitypolyethylene, acrylonitril-butadiene-styrene copolymers (ABS),polystyrene, etc. Desirably, the polypropylene is 100% virgin grade.However, it is contemplated that recycled polypropylene may be used.

c) Other Components

Besides the components noted above, still other additives may also beincorporated into the composition, such as plasticizers, fragrances,melt stabilizers, dispersion aids (e.g., surfactants), processingstabilizers, heat stabilizers, light stabilizers, UV stabilizers,antioxidants, heat aging stabilizers, whitening agents, antiblockingagents, antistatic agents, bonding agents, lubricants, fillers, etc.

B. Article Construction

The thermoplastic composition of the present invention is formed bymelt-blending together PIR and a virgin polymer. The melt blending canbe performed in a single screw extruder, a twin screw extruder, or acontinuous melt mixer.

In one aspect of the disclosure, the thermoplastic composition isproduced from a mixture of virgin polymer (e.g. 100% virgin PP) and PIRpolymers. The mixture may include from about 5% by weight PIR to about90% by weight PIR, or about 10% by weight PIR to about 80% by weightPIR. Preferably, the mixture comprises from about 20% of PIR to about80% PIR. In another aspect of the disclosure, the material is made fromabout 30 parts by weight of virgin polymer (e.g. 100% virgin PP) and 70parts by weight of the PIR (30:70), or in the alternative, the ratio maybe about 40:60, or about 50:50, or about 60:40 or about 70:30.

The melt extrusion temperature can range from the highest melting pointof the components to the lowest decomposition temperature of thecomponents. An example of the temperatures range is from about 160° C.to about 240° C.

Referring to FIG. 1, for example, one embodiment of an extruder 80 thatmay be employed for this purpose is illustrated. As shown, the extruder80 contains a housing or barrel 114 and a screw 120 (e.g., barrierscrew) rotatably driven on one end by a suitable drive 124 (typicallyincluding a motor and gearbox). One exemplary single-screw extruder 80is a BOY 22D Injection Molding Machine which may be obtained from BOYMachines, Inc., Exton, Pa. In the alternative, a twin-screw extruder maybe employed that contains two separate screws. One example of twin screwextruder is a co-rotating twin screw extruder (Werner and PfleidererCorporation, Ramsey, N.J.).

The extruder 80 generally contains three sections: the feed section 132,the melt section 134, and the mixing section 136. The feed section 132is the input portion of the barrel 114 where the polymeric material isadded. The melt section 134 is the phase change section in which theplastic material is changed from a solid to a liquid. The mixing section136 is adjacent the output end of the barrel 114 and is the portion inwhich the liquid plastic material is completely mixed. While there is noprecisely defined delineation of these sections when the extruder ismanufactured, it is well within the ordinary skill of those in this artto reliably identify the melt section 134 of the extruder barrel 114 inwhich phase change from solid to liquid is occurring.

A hopper 40 is also located adjacent to the drive 124 for supplying thevirgin polymer, SBL and other optional materials through an opening 142in the barrel 114 to the feed section 132. Opposite the drive 124 is theoutput end 144 of the extruder 80, where extruded plastic is output forfurther processing to form an article, which will be described in moredetail below.

In some aspects, a liquid component may be added to the thermoplasticcomposition, e.g fragrances, plastizers, etc. Thus, a liquid-componentsupply station 150 may be provided on the extruder barrel 114 thatincludes at least one hopper 154, which is attached to a pump 160 toselectively provide the liquid through an opening 162 to the meltsection 134. In this manner, the liquid may be mixed with the polymersin a consistent and uniform manner. Of course, in addition to or in lieuof supplying the liquid to the melt section 134, it should also beunderstood that it may be supplied to other sections of the extruder,such as the feed section 132 and/or the mixing section 136. For example,in certain embodiments, the liquid may be directly injected into thehopper 40 along with other polymeric materials.

The pump 160 may be a high pressure pump (e.g., positive displacementpump) with an injection valve so as to provide a steady selected amountof liquid to the barrel 114. If desired, a programmable logic controller170 may also be employed to connect the drive 124 to the pump 160 sothat it provides a selected volume of liquid based on the drive rate ofthe screw 120. That is, the controller 170 may control the rate ofrotation of the drive screw 120 and the pump 160 to inject the liquid ata rate based on the screw rotation rate. Accordingly, if the rotationrate of the screw 120 is increased to drive greater amounts of plasticthrough the barrel 114 in a given unit of time, the pumping rate of thepump 160 may be similarly increased to pump proportionately greateramounts of liquid into the barrel 114.

The PIR and polymeric components may be processed within the extruder 80under shear, pressure and heat to ensure sufficient mixing. For example,melt processing may occur at a temperature of from about 75° C. to about280° C., in some embodiments, from about 100° C. to about 250° C., andin some embodiments, from about 150° C. to about 200° C. Likewise, theapparent shear rate during melt processing may range from about 100seconds⁻¹ to about 10,000 seconds⁻¹, in some embodiments from about 500seconds⁻¹ to about 5000 seconds⁻¹, and in some embodiments, from about800 seconds⁻¹ to about 1200 seconds⁻¹. The apparent shear rate is equalto 4Q/πR³, where Q is the volumetric flow rate (“m³/s”) of the polymermelt and R is the radius (“m”) of the capillary (e.g., extruder die)through which the melted polymer flows. In one aspect, the desiredtemperature of the extruder-zones may be as follows: the feed zone isabout 190° C.; the compression zone is about 193° C.; the metering zoneis about 195° C.; and the final zone about 200° C.

It may be most efficient to injection-mold the melt-blend directly afterprocessing. However, it is contemplated that the melt-blendedcomposition may flow through a die to form an extrudate in the form of astrand, and be cut into pellets for later use.

Section III. Experiments

The following three materials were used to make the samples below:

1. PP: PRO-FAX SG722 Polypropylene (LyondellBasell Polymers, Houston,Tex.) having a melt flow of 25 g/10 minutes at 230° C.2. aSFL: adhesive spun-bond film laminate with a melt flow of 12 g/10minutes at 190° C.3. SBL: spun-bonded laminate with a melt flow of 10 g/10 minutes at 190°C.

Injection Molding Machine:

BOY 22D Injection Molding Machine (BOY Machines, Inc., Exton, Pa.). Thismachine has a 24.2 ton clamping force unit and a shot size of 1.2 oz.

Specimen Mold:

An ASTM D638 standard test specimen mold was used to create all testspecimens shown in FIG. 2. The specimen mold may be obtained form MasterPrecision Products, Inc., Greenville, Mich.

Samples:

The following practical examples of materials made from the PP and PIRare described to better illustrate the disclosure, without imposing anylimiting character besides those contained in the attached claims.

Comparative Example 1

The 100% virgin PP was processed using a BOY 22D Injection MoldingMachine. The temperature profile was 190° C., 193° C., 195° C. and 200°C. for extruder zones 1 through 4. The mold was set at 12.8° C. Theresulting specimens had a dull, off-white appearance with a smoothsurface. The cycle time was about 30 seconds. No processing issues wereobserved. Mold shrinkage results within 48 hours were 1.8% in the widthand 1.3% in the length.

Comparative Example 2

aSFL was processed using a BOY 22D Injection Molding Machine. Thetemperature profile was 190° C., 193° C., 195° C. and 200° C. for zones1 through 4. The mold was set at 12.8° C. The resulting specimens had adull, off-white appearance with a smooth surface. The cycle time wasabout 30 seconds. No processing issues were observed. Mold shrinkageresults within 48 hours were 0.9% in the width and 1.3% in the length.

Comparative Example 3

SBL was processed using a BOY 22D Injection Molding Machine. Thetemperature profile was 190° C., 193° C., 195° C. and 200° C. for zones1 through 4. The mold was set at 12.8° C. The resulting specimens had adull, off-white appearance with a smooth surface. The cycle time wasabout 30 seconds. No processing issues were observed. Mold shrinkageresults within 48 hours were 0% in the width and 1.2% in the length.

Example 1

The PP and aSFL materials were dry blended at 70:30 (weight ratios). Thepolymer blend was processed using a BOY 22D Injection Molding Machine.The temperature profile was 190° C., 193° C., 195° C. and 200° C. forzones 1 through 4. The mold was set at 12.8° C. The resulting specimenshad a dull, off-white appearance with a smooth surface. The cycle timewas about 30 seconds. No processing issues were observed. Mold shrinkageresults within 48 hours were 1.3% in the width and 1.7% in the length.

Example 2

The PP and aSFL materials were dry blended at 50:50 (weight ratios). Thepolymer blend was processed using a BOY 22D Injection Molding Machine.The temperature profile was 190° C., 193° C., 195° C. and 200° C. forzones 1 through 4. The mold was set at 12.8° C. The resulting specimenshad a dull, off-white appearance with a smooth surface. The cycle timewas about 30 seconds. No processing issues were observed. Mold shrinkageresults within 48 hours were 1.3% in the width and 1.8% in the length.

Example 3

The PP and aSFL materials were dry blended at 30:70 (weight ratios). Theresulting polymer blend was processed using a BOY 22D Injection MoldingMachine. The temperature profile was 190° C., 193° C., 195° C. and 200°C. for zones 1 through 4. The mold was set at 12.8° C. The resultingspecimens had a dull, off-white appearance with a smooth surface. Thecycle time was about 30 seconds. No processing issues were observed.Mold shrinkage results within 48 hours were 1.0% in the width and 1.5%in the length.

Example 4

The PP and SBL materials were dry blended at 70:30 (weight ratios)w/w.The resulting polymer blend was processed using a BOY 22D InjectionMolding Machine. The temperature profile was 190° C., 193° C., 195° C.and 200° C. for zones 1 through 4. The mold was set at 12.8° C. Theresulting specimens had a dull, off-white appearance with a smoothsurface. The cycle time was about 30 seconds. No processing issues wereobserved. Mold shrinkage results within 48 hours were 1.0% in the widthand 1.4% in the length.

Example 5

The PP and SBL materials were dry blended at 50:50 w/w. The resultingpolymer blend was processed using a BOY 22D Injection Molding Machine.The temperature profile was 190° C., 193° C., 195° C. and 200° C. forzones 1 through 4. The mold was set at 12.8° C. The resulting specimenshad a dull, off-white appearance with a smooth surface. The cycle timewas about 30 seconds. No processing issues were observed. Mold shrinkageresults within 48 hours were 1.0% in the width and 1.4% in the length.

Example 6

The PP and SBL materials were dry blended at 30:70 (weight ratios). Theresulting polymer blend was processed using a BOY 22D Injection MoldingMachine. The temperature profile was 190° C., 193° C., 195° C. and 200°C. for zones 1 through 4. The mold was set at 12.8° C. The resultingspecimens had a dull, off-white appearance with a smooth surface. Thecycle time was about 30 seconds. No processing issues were observed.Mold shrinkage results within 48 hours were 1.2% in the width and 1.4%in the length.

IZOD Test Test Method: ASTM D 256-10, “Standard Test Method forDetermining the Izod Pendulum Impact Resistance of Plastics”, TestMethod A

Test Conditions: 23±2° C., 50±10% Relative humidityConditioning: 40+ hours, 23±2° C., 50±10% Relative humidityPreparation: Machined from injection molded sample shown in FIG. 2 (IZODbar)Notch: 45° angle with an end radius of 0.010 inches

Results: As can be seen in Table 1, specimens exhibiting the mostdesirable impact strength were those made according to ComparativeExample 1 and Examples 6-8. It is shown that a 30:70 ratio of PP/SBLexhibits as much Izod Impact Strength as 100% PP, a virgin PP material,while the Izod impact strength of 100% SBL is low by comparison. Thissynergistic effect is a surprising and unexpected result. Thesynergistic effect can be more easily observed from FIG. 3. FIG. 3 is aplot of the impact strength as a function of virgin PP/SBL compositions.It shows that the binary blends of PP and SBL have three distinctcompositions (respectively at 30%, 50%, and 70% of SBL) which had Izodimpact strength higher than those expected from mixture rule (thestraight line in FIG. 3).

SBL is a desirable PIR because when combined with the virgin polymer PP,synergistic results occur that are quite surprising and unexpected. Forinstance, articles made from the blended PP/SBL material have physicalproperties that are the same as or improved over articles made from 100%virgin polymer or 100% SBL. Indeed, Izod impact tests show that anarticle made from as little as 30% wt. PP and 70% wt. SBL performssuperiorly over an article made from 100% PP or 100% SBL. In addition,the failure strain of the SBL/PP material remains relatively constantwhether the material includes 100% SBL or as little as 30% SBL, e.g.30:70 SBL/PP material.

Without being bound by theory, the synergy of combining polypropylene(“PP”) and SBL may be due to dispersed domains of thermoplasticelastomer throughout a continuous phase PP matrix. The material, made bycombining the thermoplastic elastomer with a PP matrix, possesses theunique capability to absorb the impact energy imparted during an impacttest, such as an IZOD test described herein. Because of theincompatibility between polypropylene (which does not contain aromaticstructural units) and the thermoplastic elastomer (which has polystyrenehard-segments with aromatic structural units), it is unexpected that thecombination of these materials would result in a fine dispersion ofthermoplastic elastomer within the PP matrix.

FIG. 3 shows the relationship between the impact strength as a functionof PP/SBL composition. It shows that all the mixtures impact strength isabove the straight line, as expected. This is an unexpected andsynergistic effect. Commonly, recycled polymers serve to weakenpolymeric articles made from a blend of virgin and recycled polymers.Such weakening is demonstrated by the combination of PP and aSFL.

The plot of strain at break as a function of composition is shown inFIG. 4. Once again, the middle three compositions showed synergisticeffect.

TABLE 1 Hammer Izod Impact Capacity Strength Samples (ft · lb) (ft ·lb_(f)/in) Comparative Example 1-100% PP 2.0 10.4 Example 1-PP/aSFL70:30 2.0 6.1 Example 2-PP/aSFL 50:50 2.0 2.0 Example 3-PP/aSFL 30:702.0 1.6 Comparative Example 2-100% aSFL 2.0 0.6 Example 4-PP/SBL 70:302.0 10.6 Example 5-PP/SBL 50:50 2.0 10.8 Example 6-PP/SBL 30:70 2.0 10.4Comparative Example 3-100% SBL 2.0 5.3

Tensile Test

Test method: ASTM D638 entitled “Standard Test Method For The TensileProperties Of Plastics”.Test Conditions: 23±2° C., 50±10% Relative humidityConditioning: 40+ hours, 23±2° C., 50±10% Relative humidityTest Results: Table 2 shows the tensile properties of the injectionmolded samples. The strain at break of 100% PP and 100% SBL had astrain-at-failure of 10% and 127% respectively. It was surprising thatthe blends of PP and SBL (Examples 4 to 6) had strain-at-failure valuesranging from 132% to 136%. This is unexpected synergistic effect.

FIG. 5 shows a plot of strain at break of the samples as a function ofcomposition. The straight line is expected behavior based on a mixturerule. All three blends had strain-at-failure data above the straightline, clearly demonstrating that the strain at break has a synergisticeffect. This is an unexpected result.

TABLE 2 Tensile Strain-at- Strain @ Strength failure Modulus yieldSamples (MPa) (%) (MPa) (%) Comparative Example 1 20 MPa 104% 1259 MPa4% 100% PP Comparative Example 2 22 MPa 127% 1240 MPa 4% 100% SBLExample 4 20 MPa 136% 1357 MPa 4% PP/SBL 70/30 Example 5 20 MPa 132%1294 MPa 4% PP/SBL 50/50 Example 6 20 MPa 134% 1246 MPa 4% PP/SBL 30/70

The present disclosure has been described in general and in detail bymeans of examples. Persons of skill in the art understand that thedisclosure is not limited necessarily to the embodiments specificallydisclosed, but that modifications and variations may be made withoutdeparting from the scope of the disclosure as defined by the followingclaims or their equivalents, including other equivalent componentspresently known, or to be developed, which may be used within the scopeof the present disclosure. Therefore, unless changes otherwise departfrom the scope of the disclosure, the changes should be construed asbeing included herein.

1. A method for forming a sustainable thermoplastic composition forinjection molding, the method comprising: forming a mixture by supplyinga virgin polymer and a post-industrial-recycled material (PIR) to a feedsection of an extruder, wherein the PIR comprises a thermoplastic,elastomeric-polymer and a spunbond component; and melt processing themixture within the extruder to form the thermoplastic composition. 2.The method of claim 1 wherein the thermoplastic, elastomeric-polymer isa styrenic, thermoplastic, block-copolymer.
 3. The method of claim 1wherein the thermoplastic, elastomeric-polymer is selected from thegroup consisting of a polystyrene/poly(ethylenebutylene)/polystyrene)block copolymer; a linear tri-block copolymer based on styrene,ethylene/butylene and polystyrene; a styrene-butadiene-styrene blockcopolymer, thermoplastic polyurethane, thermoplastic polyolefinelastomers and a combination thereof.
 4. The method claim 1 wherein thethermoplastic elastomeric-polymer has an average molecular weight offrom about 65,000 g/mol to about 100,000 g/mol.
 5. The method of claim 1wherein the mixture comprises 5% to 90% PIR.
 6. The method of claim 1wherein the mixture comprises 20% to 80% PIR.
 7. The method of claim 1wherein the virgin polymers are selected from the group consisting ofpolyethylene, polypropylene, polystyrene,acrylonitrile-butadiene-styrene copolymers, polylactic acid, blends ofpolylactic acid and polyolefins and combinations thereof.
 8. The methodof claim 1 wherein the step of melt processing is performed attemperatures ranging from 160° C. to 240° C. 9.-20. (canceled)
 21. Themethod of claim 1, wherein the PIR comprises a spun-bonded laminatecomprising a thermoplastic polyolefin elastomer and a spunbonded fiberlayer or an adhesive spun-bonded film laminate comprising a polyolefinfilm layer and a spunbonded fiber layer.
 22. The method of claim 21,wherein the spun-bonded laminate comprises a thermoplastic polyolefinelastomer and a spunbonded fiber layer.
 23. The method of claim 21,wherein the spun-bonded laminate comprises an adhesive spun-bonded filmlaminate comprising a polyolefin film layer and a spunbonded fiberlayer.
 24. The method of claim 1, wherein the mixture is 30 to 70 partsby weight virgin polymer.
 25. The method of claim 24, wherein the PIRcomprises the remaining parts by weight of the mixture.
 26. A method forinjection molding an article, the method comprising: forming a mixtureby supplying a virgin polymer and a post-industrial-recycled material(PIR) to a feed section of an extruder, wherein the PIR comprises athermoplastic, elastomeric-polymer and a spunbond component; meltprocessing the mixture within the extruder to form a thermoplasticcomposition; and injection molding the thermoplastic composition to formthe article.
 27. The method of claim 26, wherein the thermoplastic,elastomeric-polymer is selected from the group consisting of apolystyrene/poly(ethylenebutylene)/polystyrene) block copolymer; alinear tri-block copolymer based on styrene, ethylene/butylene andpolystyrene; a styrene-butadiene-styrene block copolymer, thermoplasticpolyurethane, thermoplastic polyolefin elastomers and a combinationthereof.
 28. The method of claim 26, wherein the virgin polymers areselected from the group consisting of polyethylene, polypropylene,polystyrene, acrylonitrile-butadiene-styrene copolymers, polylacticacid, blends of polylactic acid and polyolefins and combinationsthereof.
 29. The method of claim 26, wherein the PIR comprises aspun-bonded laminate comprising a thermoplastic polyolefin elastomer anda spunbonded fiber layer or an adhesive spun-bonded film laminatecomprising a polyolefin film layer and a spunbonded fiber layer.
 30. Themethod of claim 29, wherein the spun-bonded laminate comprises athermoplastic polyolefin elastomer and a spunbonded fiber layer.
 31. Themethod of claim 26, wherein the mixture is 30 to 70 parts by weightvirgin polymer.
 32. The method of claim 31, wherein the PIR comprisesthe remaining parts by weight of the mixture.